The industry has long had one central goal: all processes and systems should run in the most energy-efficient and cost-effective way. In addition, companies and users of motor-driven applications are increasingly confronted with stricter efficiency regulations.

The EU Commission's Regulation EU 2019/1781 on the eco-design of electric motors and frequency inverters has already placed stricter requirements on these products in terms of energy efficiency. The 2019 regulation relates to low-voltage asynchronous motors with an AC voltage of less than 1,000 V and to frequency converters (drives with speed control). In 2020, amendments to Regulation EU 2019/1781 were published, which provided some clarification for frequency inverters. The regulation has been implemented in two stages since July 1, 2021. The second stage, which further expands the scope and increases the requirements for motors, will come into force on July 1, 2023.

The Sustainable Product Initiative is an important element for more resource and climate protection. The aim of the initiative is to make products placed on the EU internal market more sustainable. In addition to energy efficiency, particular emphasis is placed on features such as durability, reusability, reparability, recyclability and longevity. These criteria are already defined in the DIN EN 4555x series of standards on the material efficiency of energy-related products.

Creating verifiable environmental statements

Further building blocks are now being added in line with this: According to the new Substantiating Green Claims Initiative, companies are to substantiate their environmental claims using an EU-wide method. According to this regulation, the environmental labels and evidence provided by companies, such as the criteria mentioned above, should be reliable, comparable and verifiable throughout the EU. Instead of comparing "apples with pears", as has often been the case in the past, it will be possible to compare "apples with apples".

The new regulation aims to prevent companies from making inaccurate statements about the environmental footprint of their products in the future. According to the Commission's current proposal, companies will in future be required to verify their claims using the standardized "Product Environmental Footprint" (PEF) method. This involves using 16 environmental impact criteria to measure the ecological footprint of a product over its entire life cycle. This would enable product users to make their purchasing decisions on the basis of comparable information.

_{CO2 footprint} is becoming increasingly important

It is becoming increasingly relevant for companies to know and objectively consider the_{CO2 footprint} of their systems. This applies in particular to drive technology products. According to an ABB analysis, around 98% of the_{CO2 footprint} of frequency inverters and motors is generated during the use phase of the products and only 2% during the manufacturing phase. For high-performance products, the ratio can even be 99% to 1%. This means that a product with a higher_{carbon footprint} in production, but which is energy-efficient in operation, can perform significantly better over a useful life of 15, 20 or 40 years than a less energy-efficient product with a more favorable_{carbon footprint} in production.

For capital goods in particular, it is necessary to estimate the system utilization over the entire lifetime. Focusing on lower investment costs and the smallest possible initial_{CO2 footprint} is not enough to achieve the best possible environmental effect in the long term.

For many companies, their own sustainability goals are becoming increasingly important. This is expressed, among other things, in the Environmental Product Declarations, which not only provide information about the functional and technical properties of their products, but also about their life cycle assessment parameters. ABB supports companies on their way to climate-neutral production by providing suitable solutions through life cycle assessments of ABB products.

Before purchasing, detailed technical advice can ensure that, for example, the right frequency inverter is selected and dimensioned to achieve maximum efficiency and performance for a process. This should not only reduce operating costs, but also energy consumption. For example, if a machine manufacturer wants its systems not to exceed a specified energy consumption and thus_{CO2 emissions} over their service life, ABB will help it to find the most efficient solution for the application. Important aspects here are the load conditions of machines, in particular their duration and intensity of utilization. For example, it makes a difference whether a drive solution is only in operation for a few dozen hours a year in order to adjust something as required or whether a pump runs for 20 years without interruption.

The material efficiency indicators are further points of reference that can serve as a benchmark for an effective materials and circular economy. Keyword durability: A more durable product can be used for much longer before it disappears from the market again. ABB therefore offers services to extend the service life of all its drive products. Retrofitting drives serves to increase their performance, extend their functionality and prolong their service life.

Modernize old drives with new components

Instead of replacing a complete drive or drive system, it often makes more sense to modernize the old system by reusing all relevant parts of the original equipment and purchasing the required new components. As part of such a measure, the cabling, motors and control cabinets are often reused, while the frequency inverters or electronics are completely or partially replaced with the latest technology. Upgrading to the latest controller version usually makes sense in order to be able to use new functionalities.

Last but not least, with a view to the materials and circular economy, there is a growing demand for improved recyclability of drive products. This is because old motors in particular consist of large quantities of recyclable materials. It will not be possible to recycle a motor 100%, as it will always contain components that cannot be recycled, such as sealing rings or epoxy resins. Nevertheless, the recycling rate of an engine can be increased from 95% to 98% if specific recycling expertise is available.

This requires recycling companies as partners that have the appropriate processes, such as for aluminum and copper, but also for rare earths, such as those used in synchronous motors.

Massive energy savings

ABB works with partners around the world who recycle and dispose of ABB drives and associated equipment on site in the best possible way. The recycling of metals enables massive energy savings compared to their new production, while the recycled metals can be reused for new motors or other products.

With the Sustainable Product Initiative, the EU Commission is aiming to make products more sustainable. A new regulation as part of the initiative is intended to enable objective comparability of statements on the environmental impact of products. ABB supports the pursuit of sustainable and efficient design of industrial processes and helps companies to meet important criteria for an effective materials and circular economy.